Battery pack and manufacturing method therefor

ABSTRACT

A battery pack has a battery obtained by packing a battery element with a packing member. The battery element is formed by winding or laminating an anode and a cathode through separators. The battery pack includes frame member surrounding the packing member packing the battery element and a coating layer constituted of a curable resin formed on surfaces of the packing member which are surrounded and demarcated by the frame member.

CROSS REFERENCES TO RELATED APPLICATIONS

The present application claims priority to Japanese Patent ApplicationNo. 2008-017289 filed in the Japanese Patent Office on Jan. 29, 2008,the entire content of which being incorporated herein by reference.

BACKGROUND

The present application relates to a battery pack containing therein abattery such as, e.g., a nonaqueous electrolyte secondary battery, and amanufacturing method therefor. More particularly, the presentapplication relates to a battery pack having a battery obtained bypacking a battery element, which is formed by winding or laminating ananode and a cathode through separators, with a packing member, and amanufacturing method therefor.

In recent years, many portable electronics, such as camera-incorporatedvideo tape recorders, portable telephones, and portable computers, havebeen marketed, and efforts have been made to make them smaller andlighter.

As electronics become small and light, a battery pack used as theirportable power supply demands not only high energy but also smaller sizeand lighter weight. Among batteries used for such a battery pack is alithium ion secondary battery having high capacity.

In the lithium ion secondary battery, a battery element having an anodeand a cathode capable of doping/dedoping lithium ions is sealed in ametallic can or a metallic laminate film, and control is performed by acircuit board electrically connected to the battery element.

Furthermore, some related-art lithium ion secondary batteries areconfigured such that a lithium ion secondary battery is encased in acasing vertically split into two parts, together with a circuit board toform a battery pack (see, e.g., Japanese Patents Nos. 3556875, 3614767,and 3643792).

By the way, in related-art lithium ion secondary batteries such asmentioned above, those using the metallic can for sealing the batteryelement can easily ensure high dimensional accuracy, but are slightlythicker and heavier.

Meanwhile, those using the metallic laminate film for sealing thebattery element are thinner and lighter than those using the metalliccan, but have shortcomings that it is difficult to increase thedimensional accuracy due to large variations in the size of the batteryelement, and hence that their mechanical strength is low.

Furthermore, in those related-art battery packs in which the lithium ionsecondary battery and the circuit board are encased in the casing, thecasing need be thick enough to protect the lithium ion secondary batteryand the circuit board from external shock and the like.

In addition, even in bonding the vertically split parts of the casingwith a double-sided adhesive tape, by ultrasonic fusion-bonding, or thelike, the casing need be thick enough to accommodate these methods.Hence, the thickness and weight of the battery pack as a whole increase,thereby imposing an issue that such batteries are not suitable as theportable power supply.

In coating a resin integrally on surfaces of a battery as a packagingmaterial, a metallic can and the resin are integrally molded usingmolds, as disclosed in, e.g., Japanese Patents Nos. 3556875, 3614767,and 3929839.

However, there have been three roughly identified issues: (a) when afilm-shaped packing member is used instead of a metallic can, thepacking member as a middle member has a large dimensional tolerance sothat its positioning is difficult; (2) the strength of the packingmember is inferior so that injection pressure cannot be increased duringmolding; and (3) the film-shaped packing member for which an aluminumlaminate film is typically used has its surface formed of nylon, aresin, such as polyethylene terephthalate, polypropylene, or the like,so that it is not easily bondable to the resin for molding.

SUMMARY

Accordingly, it is desirable to provide a battery pack and amanufacturing method therefor, capable of forming a uniformly thickcoating layer on the surface of a packing member, without using molds orthe like, and also capable of realizing high dimensional accuracy andhigh mechanical strength, as well as light weight and low cost.

In one embodiment, there is provided a battery pack having a batteryobtained by packing a battery element with a packing member, wherein thebattery element is formed by winding or laminating an anode and acathode through separators. The battery pack includes a frame membersurrounding the packing member packing the battery element therewith,and a coating layer formed of a curable resin on surfaces of the packingmember which are surrounded and demarcated by the frame member.

In another embodiment, there is provided a manufacturing method for abattery pack having a battery, a frame member, and a coating layer, inwhich the battery is obtained by packing a battery element with apacking member, the battery element is formed by winding or laminatingan anode and a cathode through separators, the frame member surroundsthe packing member packing the battery element therewith, and thecoating layer is formed of a curable resin on surfaces of the packingmember which are surrounded and demarcated by the frame member. Themanufacturing method includes the steps of forming the coating layer tobe formed on the surfaces of the packing member by rotating the packingmember about a dripping point from which the curable resin is dripped,and thereafter curing the curable resin.

According to the above-mentioned embodiments, a battery pack and amanufacturing method therefor can be provided, in which a uniformlythick coating layer can be formed on the surfaces of the packing memberwithout using molds, and high dimensional accuracy and high mechanicalstrength, as well as light weight and low cost can be realized.

Additional features and advantages are described herein, and will beapparent from the following Detailed Description and the figures.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A is a plan view of a battery pack according to an embodiment;

FIG. 1B is a front sectional view showing an internal structure of thebattery pack;

FIG. 1C is a sectional view taken along a line I-I shown in FIG. 1A;

FIG. 2 is an enlarged view of a portion indicated by a surrounding lineII in FIG. 1C;

FIG. 3 is a perspective view showing a structure of a battery element;

FIG. 4 is a perspective view showing the same battery element and apacking member;

FIG. 5A is an explanatory diagram outlining a construction of an examplespin coater;

FIG. 5B is a schematic plan view showing a turntable and a battery packbefore a coating layer is formed thereon, which is placed on theturntable;

FIG. 6A is a plan view of a battery pack in which surfaces of itspacking member are not roughened;

FIG. 6B is an explanatory diagram showing a relationship between thethickness of the packing member and the thickness of a coating layer;

FIG. 7A is a plan view of a battery pack in which surfaces of itspacking member are roughened;

FIG. 7B is an explanatory diagram showing a relationship between thethickness of the packing member and the thickness of a coating layer;

FIG. 8A is a plan view of a battery pack in which surfaces of itspacking member are roughened;

FIG. 8B is an explanatory diagram showing a relationship between thethickness of the packing member and the thickness of a coating layer;

FIG. 9A is a plan view of a battery pack in which surfaces of itspacking member are roughened;

FIG. 9B is an explanatory diagram showing a relationship between thethickness of the packing member and the thickness of a coating;

FIG. 10A is a plan view of a battery pack in which surfaces of itspacking member are roughened;

FIG. 10B is an explanatory diagram showing a relationship between thethickness of the packing member and the thickness of a coating layer;

FIG. 11A is a plan view of a battery pack in which surfaces of itspacking member are roughened;

FIG. 11B is an explanatory diagram showing a relationship between thethickness of the packing member and the thickness of a coating layer;

FIG. 12A is a plan view showing an example of grooves for making thethickness of a coating uniform;

FIG. 12B is a plan view showing another example of grooves; and

FIG. 12C is an explanatory diagram showing a relationship between thethickness of a packing member and the thickness of the coating layer.

DETAILED DESCRIPTION

The present application will be described below with reference to thedrawings according to an embodiment. FIG. 1A is a plan view of a batterypack according to an embodiment, FIG. 1B is a front sectional viewshowing an internal structure of the battery pack, and FIG. 1C is asectional view taken along a line I-I shown in FIG. 1A. FIG. 2 is anenlarged view of a portion indicated by a surrounding line II in FIG.1Cs. FIG. 3 is a perspective view showing a structure of a batteryelement. FIG. 4 is a perspective view showing the battery element and apacking member.

A battery pack A according to an embodiment has a nonaqueous electrolytesecondary battery (hereinafter called simply as “battery”) 20, and aframe member 30 surrounding this battery 20.

The battery 20 is of a polymer type formed by packing a battery element10 with a packing member 40. The battery element 10 is formed by windingor laminating an anode 11 and a cathode 12 through separators 13 a, 13b. The battery 20 is formed into a rectangular shape in the presentembodiment (see FIGS. 3, 4).

More specifically, the battery element 10 is formed by sequentiallylaminating the belt-shaped anode 11, the separator 13 a, the belt-shapedcathode 12 arranged to face the anode 11, and the separator 13 b, andwinding the resultant laminate in a longitudinal direction. The anode 11and the cathode 12 each have both surfaces thereof coated with a gelelectrolyte 14.

An anode terminal 15 a connected to the anode 11 and a cathode terminal15 b connected to the cathode 12 extend from the battery element 10. Theanode terminal 15 a and the cathode terminal 15 b are covered withsealants, not shown, each being a strip of resin such as maleicanhydride-modified polypropylene (PPa), in order to enhance adhesion tothe packing member 40 (see FIG. 4).

The packing member 40 shown in the present embodiment is an aluminumlaminate film, formed of a rectangular front plate 41 as viewed inplane, and a flat back plate 42 identically shaped and foldablymonolithic with this front plate 41.

A length-to-width ratio L1/L2 of the packing member 40 shown in thepresent embodiment is set to be not less than 1 and not more than 1.3,where L1 is the long length and L2 is the short length.

When the four sides are equal in length in terms of the long and shortlengths, L1/L2=1, and not less than 1.

The ratio L1/L2 is preferably be not more than 1.5, or more preferablynot more than 1.3.

The closer the ratio L1/L2 is to 1, the more equidistant the respectivesides are to a rotation center, allowing a resin for coating to be moreevenly spread and hence preventing its thickness variations andfacilitating the manufacture.

Conversely, if the ratio L1/L2 exceeds 1.5, assuming L1 is the longlength and L2 is the short length, the resin tends to be thinner alongthe long sides than along the short sides, preventing the packing memberfrom having a good appearance as a product and a required strength. Ifthe resin is coated thicker overall to provide the required strength, ademerit arises that the volumetric energy density as the battery pack isimpaired.

The front plate 41 is formed such that a casing portion 43 encasing thebattery element 10 is projected, and a fusion-bonding portion 44 havinga certain width extends all around the casing portion 43.

The front plate 41 and the back plate 42 are intimately sealed with eachother by the front plate 41 being, e.g., thermally fusion-bonded, alongthe short sides of its fusion-bonding portion 44, to the back plate 42.

A laminate film having a single layer or two or more layer films may beusable. In the present embodiment, the laminate film includes apolyolefin film.

Surfaces 43 a, 42 a of the casing portion 43 formed on the packingmember 40 are roughened such that the thickness of a later-describedcoating layer C becomes uniform. For the surface roughness, anarithmetic average roughness is set such that the thickness of thecoating C becomes uniform.

In the present embodiment, the surface roughness is preferably set tonot less than 1 μm and not more than 50 μm in terms of the arithmeticaverage roughness Ra specified by JIS B 0601.

On the basis of this setting, one can control the thickness of the resincoated consistently by a centrifugal force derived from rotation.

If the arithmetic mean roughness Ra is equal to or less than 1 μm, thecentrifugal force is not affected so much as to control the resinthickness.

In that case, the ratio L1/L2, assuming L1 as long length and L2 as theshort length, is desirably close to 1, and L1 is desirably as short asnot more than 5 mm.

Furthermore, if the arithmetic average roughness Ra exceeds 50 μm, thespreading of the resin by the centrifugal force is limited so much andthickness variations in the resin coating are rather aggravated.

The arithmetic mean roughness Ra for the surface roughness specified byJIS B 0601 is calculated as follows.

First, the battery pack A is cut perpendicular to its largest surface toobtain a section.

The obtained section is imaged by an electron microscope, and roughnesscurves for sections of the surfaces 43 a, 42 a of the packing member 40are checked compliant with what is defined in JIS B 0601. Then, sums oftop heights and bottom depth in the respective roughness curves areobtained, and these sums, i.e., the roughness values are averaged,thereby calculating the arithmetic average roughness Ra.

It is noted that any height, for which the ratio of the smallest heightto the largest height is not more than 10% according to JIS B 0601, isnot included in the average calculation.

In the present embodiment, the surface roughness is gradually decreasedtoward an outside edge portion 43c of the casing portion 43 from alater-described dripping point O from which a curable resin is to bedripped.

The coating layer C is formed by curing the curable resin on thesurfaces 43 a, 44 a, 42 a of the packing member 40 surrounded anddemarcated by the frame member 30, details of which will be describedlater.

As the curable resin, e.g., in addition to a urethane resin, an acrylicresin, an epoxy resin, and the like may be adopted. In the presentembodiment, the coating C is formed of a composite material containingthe resin and fillers, such as metallic oxide or metallic nitride.

The curable resin may preferably contain, as a component resin, apolymer having affinity, compatibility, and reactability with thefillers such as metallic oxide or metallic nitride, as well as havinghigh dimensional accuracy and strength.

For example, a urethane resin, an acrylic resin, or an epoxy resin maysuitably be used as a shape keeping polymer (polymer film). It is notedthat the shape keeping polymer may be any of those having goodadhesiveness to the metallic laminate film and superior in dimensionalstability and moldability.

On the other hand, as inorganic fillers, oxides of silicon (Si),aluminum (Al), titanium (Ti), zirconium (Zr), zinc (Zn), and magnesium(Mg), or any arbitrary mixture of these oxides may be cited. Suchmetallic oxide fillers function to improve the hardness of the coatinglayer C, and are arranged in contact state with the shape keepingpolymer. For example, these inorganic fillers may be mixed into theshape keeping polymer. In this case, the fillers are preferablydispersed evenly in the whole of the shape keeping polymer.

It is also preferable to use fillers having superior transparency when aphoto-curing resin is used as a reaction-curable resin.

The mixing amount of the inorganic fillers may be variable according tothe type of the shape keeping polymer. However, if the mixing amount isless than 3% with respect to the mass of the shape keeping polymer, thecoating layer may not be hard enough, while if the mixing amount exceeds60%, issues such as moldability and the brittleness of ceramic duringmanufacture may arise. Consequently, the mixing amount of the inorganicfillers to the mass of the shape keeping polymer may preferably be about3-60%.

Furthermore, if the average grain diameter of the inorganic fillers isdecreased, the hardness increases but chargeability during molding isaffected, thereby potentially impairing the productivity. Meanwhile, ifthe average grain diameter of the inorganic fillers is increased, thetarget strength is hard to obtain, whereby there is a potentially thatthe dimensional accuracy as the battery pack is adversely affected.Considering these factors, the average grain diameter of the inorganicfillers may preferably be set to be 0.5-40 μm, or more preferably to2-20 μm.

Furthermore, the inorganic fillers may be variously shaped, such asbeing spherical, scale-shaped, plate-shaped, and needle-shaped.Spherical fillers, although not particularly limited thereto, arepreferable in that they are easy to produce and inexpensively availablein a uniform average grain diameter. Needle-shaped fillers having a highaspect ratio are preferable in that they can easily increase thestrength as fillers. Scale-shaped fillers are also preferable in thattheir chargeability can be increased with increasing filler content. Itis noted that fillers having different average grain diameters ordifferently shaped fillers may be used by mixture, according todifferent applications.

As described above, the coating layer C may desirably have a shapekeeping polymer and predetermined inorganic fillers, but may alsocontain various additives in addition to them. For example, a UVabsorbent, a light stabilizer, a curing agent, or any mixture thereofmay be added in the shape keeping polymer so that the shape keepingpolymer can coexist with the metallic oxide fillers, a stabilizer, alubricant, a processing aiding material, a plasticizer, a shockresistant aiding material, a colorant, the UV absorbent, and the like.

In the present embodiment, a thickness t of the coating layer C is setto not more than 1000 μm.

If the thickness of the coating layer C exceeds 1000 μm, for even thebattery pack to which this coating layer C is formed, it may be hard toexhibit its merit in terms of the volumetric energy density. Thethickness of the coating layer C is more preferably not more than 300μm. A thinner coating layer C is better, as long as the requiredmechanical strength and shock resistance can be satisfied.

When the coating layer C is formed only by natural dripping with alater-described spin coat apparatus 50, it is more preferable that theresin to be dripped have a lower viscosity. It is also preferable thatthe surfaces of the packing member 40 be hydrophilic, not repellentagainst the liquid resin. If these two requirements cannot be met, thedripping pressure is adjusted and the pressure is increased if the resinis highly viscous and highly water-repellent.

By the way, the frame member 30 is formed by framing side framingmembers 31, 31, and upper framing member 32 and a lower framing member33. The side framing members 31, 31 are spaced apart so as to sandwichthe packing member 40 of the battery 20 from both sides. The upper andlower framing members 32, 33 are spaced apart so as to sandwich thepacking member 40 vertically. The upper and lower framing members 32, 33are assembled to both upper and lower ends of the side framing members31, 31. These framing members are integrally formed using apredetermined resin (see FIGS. 1B, 1C).

The upper framing member 32 has a below-described circuit protectingboard 60 embedded therein.

The circuit protecting board 60 includes a primary protecting circuitand a secondary protecting circuit, and also a PTC (Positive TemperatureCoefficient), if necessary.

The primary protecting circuit, not shown, has functions of preventingovercharging to the battery element 10 and over-discharging toelectronic equipment, not shown, from the battery element 10 when thebattery element 10 of the battery pack A attached to the electronicequipment is charged.

The secondary protecting circuit, not shown, has a power supply fuse forstopping overcurrent when the overcurrent flows, and a temperature fusefor stopping supply of current when the use temperature of the batteryelement 10 becomes higher than predetermined value.

Furthermore, the PTC is arranged in the secondary protecting circuit,and is an example return type protecting element for electricallyprotecting the battery element 10.

That is, the PTC has a function of drastically increasing its resistancevalue when heated with temperature not less than predetermined degree,and serves to prevent issues caused by short-circuits between the anodeand the cathode due to temperature rise, e.g., when the battery element10 is heated due to external short-circuits or the like.

The above-mentioned circuit protecting board 60 is embedded in the upperframing member 32 in the process of forming the frame member 30.

It is noted that the upper framing member 32 and the lower framingmember 33 may also have a buffer, not shown, embedded therein, thebuffer serving to protect the protecting circuit board 60 and thebattery 20.

A manufacturing method for the thus configured battery pack A will bedescribed with reference to FIGS. 5A, 5B. FIG. 5A is an explanatorydiagram outlining a configuration of an example spin coater, and FIG. 5Bis a schematic plan view showing a turntable and the battery pack beforethe coating layer is formed thereon, which is placed on the turntable.

According to the example, spin coater 50 includes a turntable 51 rotatedas driven by a motor 55 and the like, a nozzle 52 aligned with arotation center axis O of the turntable 51, a dripping adjuster 53 fortemporarily storing the resin for forming the coating layer C anddripping a predetermined amount of the resin from the nozzle 52, and acontroller 54 controlling the turntable 51 and the dripping adjuster 53,as its main components.

The controller 54 has a control function of increasing/decreasing thenumber of revolutions of the turntable 51 according to the resin to bedripped and the like, an adjustment function of increasing/decreasingthe dripping amount of, and hence the dripping pressure for, the resinto be dripped via the dripping adjuster 53, by executing predeterminedprograms.

The coating layer is formed by the thus configured spin coat apparatus50 in the following way.

First, after packing the battery element 10 with the packing member 40,the front plate 41 of the packing member 40 is intimately sealed, alongits fusion-bonding portion 44, with the back plate 42 by thermalfusion-bonding or the like, thereby assembling the battery 20.

Next, the coating layer C is formed on the surfaces 43 a, 42 a of thepacking member 40 of the thus assembled battery 20.

Namely, the packing member 40 is fixed in place on the turntable 51,with the center of the casing portion 43 of the packing member 40 of thebattery 20 fitted into the frame member 30, aligned with the rotationcenter axis O of the turntable 51.

The battery 20 is fixed to the turntable 51 by connecting a vacuum pump,not shown, into a sucking hole, not shown, formed at a fixing positionof the turntable 51, and sucking a battery pack A′ before the coatinglayer is formed thereon, to the turntable 51.

It is noted that the vacuum pump, not shown, may be driven by thecontroller 54 or manually.

Then, while rotating the turntable 51 at a predetermined number ofrevolutions, a predetermined amount of the curable resin is dripped ontothe surfaces 43 a, 42 a of the packing member 40.

The dripped curable resin is spread over the surfaces 43 a, 42 a of thepacking member 40 by a centrifugal force, thereby forming the coatinglayer C evenly over these surfaces 43 a, 42 a, and also driving off aredundant curable resin portion over the packing member 40 so that aspace demarcated by the frame member 30, the casing portion 43, and thefusion-bonded portion 44 is loaded therewith.

In the process of dripping the curable resin, the turntable 51 isrotated preferably at a relatively low speed of about 20-100 rpm (SIunit: S⁻¹). Immediately after the dripping (injection), the motor 55 isdriven and controlled by the controller 54 to increase the rotationalspeed so that a uniform layer is formed.

The rotational speed during the spin coating is intimately related withthe thickness of the light-transmissive layer to be formed. The higherthe rotational speed is, the thinner the formed coating layer becomes.Meanwhile, the curable resin is not particularly limited, and anyurethane or epoxy acrylate resin may be usable.

After the rotation of the turntable 51 is stopped, the coating layer isirradiated with rays from, e.g., a UV lamp, not shown, to cure the UVcurable resin forming the coating layer C. As a result, the battery packA is completed.

The UV curable resin is made of, e.g., urethane or epoxy acrylate. Theviscosity of the UV curable resin is selected from 50-1000 mPa·(SIunit), preferably from 700-800 mPa·s.

The viscosity values of the UV curable resin are effective at 25° C. Inaddition, its glass transition temperature may range from 45-130° C., orpreferably 75-110° C.

It is noted that when the coating layer C is formed of a thermosettingresin, the resin is cured by heating with an oven, not shown, instead ofthe UV lamp.

According to the battery pack A which is an embodiment, a high-strengthbattery pack with a coating layer thinner than the related-art examplescan be realized, and a smaller and lighter battery pack can also berealized.

Furthermore, by using any of a UV absorbent, a light stabilizer, and acuring agent together with metallic oxide fillers such as mentionedabove, and by using any of resins such as a urethane resin, an acrylicresin, and an epoxy resin, the coating is made thinner than a metallicplate, and can be processed at high productivity.

For these reasons, not only the energy density of the obtained batteryis improved, but also the yield is improved owing to ease of formationand high dimensional accuracy of the battery pack. In addition, thedegree of freedom can be increased in designing the size, shape, andstrength of the battery pack to accommodate various applications.

By the way, an example in which the surfaces of the packing member areroughened to make the coating layer uniformly thick has been describedin the above embodiment. Now, a comparative example is shown below inwhich surfaces of a battery pack are not roughened. FIG. 6A is a planview of a battery pack A0 in which surfaces of its packing member arenot roughened, and FIG. 6B is an explanatory diagram showing arelationship between the thickness of the packing member and thethickness of a coating layer. FIG. 7A is a plan view of a battery packA1 in which surfaces of its packing member are roughened, and FIG. 7B isan explanatory diagram showing a relationship between the thickness ofthe packing member and the thickness of a coating layer. It is notedthat in FIGS. 6B, 7B, (a) denotes the thickness of the coating layer and(b) denotes the thickness of the packing member, and an abscissa axiscorresponds to a distance W from the rotation center axis O to anoutside edge portion (long side) 43 c shown in FIGS. 6A, 7A.

The packing member A1 of the battery pack shown in FIG. 7A has itssurface roughness varied concentrically from the rotation center axis O.When compared with the battery pack A0 shown in FIG. 6A, it is apparentthat the packing member A1 exhibits smaller thickness variations in thecoating layer.

The packing member in which its surface roughness is variedconcentrically from the rotation center axis O to make the coating layeruniformly thick has been described in FIGS. 7A, 7B. Instead, packingmembers shown in FIGS. 8A, 8B to 11A, 11B may also be acceptable. It isnoted that parts and components equivalent to those described in theabove embodiment are denoted by the same reference numerals, and theirdetailed description will be omitted.

FIG. 8A is a plan view of a battery pack A2 in which surfaces of itspacking member are roughened, and FIG. 8B is an explanatory diagramshowing a relationship between the thickness of the packing member andthe thickness of a coating layer.

In a surface of the packing member 40 of the battery pack A2, a surfacearea from a point between a rotation center axis O and an outside edgeportion 43 c, to the outside edge portion 43 c is made into a roughsurface roughness.

FIG. 9A is a plan view of a battery pack A3 in which surfaces of itspacking member are roughened, and FIG. 9B is an explanatory diagramshowing a relationship between the thickness of the packing member andthe thickness of a coating layer.

In a surface of the packing member 40 of the battery pack A3, a surfacearea from a rotation center axis O to a point between the rotationcenter axis O and an outside edge portion 43 c is made into a finesurface roughness, and also a surface area from the point to the outsideedge portion 43 c is made into a rough surface roughness.

In this case, a large change in the thickness of the coating layer Cnear the outside edge portion 43 c of the packing member 40 can besuppressed, and also its thickness variations become small.

FIG. 10A is a plan view of a battery pack A4 in which surfaces of itspacking member are roughened, and FIG. 10B is an explanatory diagramshowing a relationship between the thickness of the packing member andthe thickness of a coating layer.

In a surface of the packing member 40 of the battery pack A4, a surfacearea from a rotation center axis O to a point between the rotationcenter axis O and an outside edge portion 43 c is made into a roughsurface roughness, and also a surface area from the point to the outsideedge portion 43 c is made into a fine surface roughness.

FIG. 11A is a plan view of a battery pack A5 in which surfaces of itspacking member are roughened, and FIG. 11B is an explanatory diagramshowing a relationship between the thickness of the packing member andthe thickness of a coating layer.

In a surface of the packing member 40 of the battery pack A5, a surfacearea from a rotation center axis O to a point between the rotationcenter axis O and an outside edge portion 43 c is made into a roughsurface roughness, and also a surface area from the point to the outsideedge portion 43 c is made into a fine surface roughness.

In this case, a large increase in the thickness of the coating layer Cnear the outside edge portion 43 c of the packing member 40 can beeliminated, and also its thickness can be flattened and its thicknessvariations become small.

In FIGS. 7A-11B mentioned above, the battery packs in each of which thesurface roughness of the packing member is varied to make the thicknessof the coating layer uniform have been described. Battery packs such asshown in FIGS. 12A, 12B may also be acceptable, in each of which groovesare formed in surfaces of the packing member to make the thickness of acoating layer uniform.

FIG. 12A is a plan view showing an example of grooves for making thethickness of the coating layer uniform, FIG. 12B is a plan view showinganother example of grooves, and FIG. 12C is an explanatory diagramshowing a relationship between the thickness of a packing member and thethickness of the coating layer.

A packing member 40 of a battery pack A6 shown in FIG. 12A has cubicgrooves 60 . . . formed in array on a surface 43 a thereof so as to bespaced apart from each other at a predetermined equal angle space alongthe circumference of each of two circles having different radii, near arotation center axis O.

Also, a packing member 40 of a battery pack A6 shown in FIG. 12B hascubic grooves 60 . . . formed in array on a surface 43 a thereof so asto be spaced apart from each other at equal intervals along an outsideedge portion 43 a of a casing portion 43.

With the grooves 60 shown in any of FIGS. 12A, 12B, a coating layerexhibiting small thickness variations can be formed, as shown in FIG.12C.

TABLE 1 INTER- SURFACE MEDIATE ROUGH- SURFACE SURFACE NESS ROUGHNESSROUGHNESS CHANGE Ra AT Ra BETWEEN Ra ALONG IN BATTERY ROTATION CENTERRECTAN- SURFACE THICK- CURING CURING VISCOSITY CENTER PORTION GULAR SIDEROUGH- NESS RESIN METHOD TIME mPa · s PORTION AND SIDES PORTIONS NESS(mm) EXAMPLE EPOXY LEFT AT  1 DAY 1200 0.5 0.5 0.5 NONE 5 1 AMBIENTTEMPER- ATURE EXAMPLE EPOXY UV RAYS  5 SECONDS 40 0.9 0.9 0.9 NONE 5 2EXAMPLE EPOXY 90° C.  5 MINUTES 1000 52 52 52 NONE 5 3 EXAMPLE ACRYL UVRAYS 15 SECONDS 50 1 1 1 NONE 5 4 EXAMPLE URETHANE UV RAYS 10 SECONDS 7050 50 50 NONE 5 5 ACRYLATE EXAMPLE URETHANE 70° C.  3 MINUTES 800 0.50.5 15 1 STEP 5 6 EXAMPLE URETHANE 70° C.  2 MINUTES 100 15 15 0.5 1STEP 5 7 EXAMPLE EPOXY 70° C.  1 MINUTE 100 15 15 30 1 STEP 5 8 EXAMPLEACRYL UV RAYS  5 SECONDS 100 30 30 15 1 STEP 5 9 EXAMPLE ACRYL UV RAYS 5 SECONDS 100 0.5 10 30 2 STEPS 5 10 EXAMPLE URETHANE UV RAYS  5SECONDS 100 30 10 0.5 2 STEPS 5 11 ACRYLATE DIMENSIONAL 10-TIMES CHANGEΔt EFFECTS (REFERENCE) DROP- AFTER LENGTH- VARIATIONS PING 50-TIMES TO-IN THICKNESS RATED TEST DROPPING BATTERY BATTERY WIDTH COATED AFTERENERGY FROM TEST FROM LENGTH WIDTH RAIO OF SURFACES PACKING COATINGDENSITY HEIGHT HEIGHT (mm) (mm) BATTERY (um) MEMBER (um) (Wh/l) OF 2 mOF 1.2 m EXAMPLE 35 69 1.97 30 ALMINUM 150 505 OK FOR CRACK/1.2 1LAMINATE ALL 10 EXAMPLE 34 50 1.47 30 ALMINUM 150 505 OK FOR CRACK/1.2 2LAMINATE ALL 10 EXAMPLE 34 43 1.26 20 ALMINUM 150 505 OK FOR CRACK/1.2 3LAMINATE ALL 10 EXAMPLE 34 38 1.12 15 ALMINUM 150 505 OK FOR 0.9 4LAMINATE ALL 10 EXAMPLE 34 38 1.12 15 ALMINUM 100 525 OK FOR 0.8 5LAMINATE ALL 10 EXAMPLE 34 38 1.12 12 ALMINUM 80 545 OK FOR 0.4 6LAMINATE ALL 10 EXAMPLE 34 38 1.12 11 ALMINUM 50 555 OK FOR 0.4 7LAMINATE ALL 10 EXAMPLE 34 38 1.12 8 POLYETHYL- 50 570 OK FOR 0.2 8 ENEFILM + ALL 10 PET FILM EXAMPLE 34 36 1.06 5 POLYETHYL- 50 620 OK FOR 0.19 ENE FILM ALL 10 (SINGLE EXAMPLE 34 36 1.06 5 POLYETHYL- 50 620 OK FOR0.1 10 ENE FILM ALL 10 (SINGLE EXAMPLE 34 36 1.06 2 POLYETHYL- 50 620 OKFOR 0.1 11 ENE FILM ALL 10 (SINGLE

Table 1 shows relationships between factors and test results. Thefactors are the above-mentioned curable resin, curing method, curingtime, viscosity, surface roughness at rotation center portion,intermediate surface roughness between center portion and sides, surfaceroughness along rectangular side portions, change in surface roughness,battery length, battery width, length-to-width ratio of battery,variations in coated surfaces, material of packing member, thicknessafter coating, and rated energy density. The results of a test in whichbattery packs were dropped 10 times from a height of 2 meters are shown.For reference, dimensional change after a test in which the batterypacks were dropped 50 times from a height of 1.2 meters is additionallyshown.

It is noted that the “intermediate surface roughness between centerportion and sides” means a surface roughness at an intermediate positionbetween the rotation center axis O and the outside edge portion 43 a,and the “surface roughness along rectangular side portions” issynonymous with a surface roughness near the outside edge portion 43 a.

As is apparent from Table 1 shown above, according to Examples 1-11pertaining to the present application, an evenly thick coating can beformed on the surfaces of the packing member without use of molds or thelike.

Also, high dimensional accuracy, high mechanical strength, as well assmall weight and low cost can be realized.

While the example in which the coating layer is formed by a spin coatingmethod has been described in the above embodiment, other formationmethods may be applicable. Specifically, such other methods include rollcoating, die coating, dip coating, spray coating, casting, and the like.

It should be understood that various changes and modifications to thepresently preferred embodiments described herein will be apparent tothose skilled in the art. Such changes and modifications can be madewithout departing from the spirit and scope of the present subjectmatter and without diminishing its intended advantages. It is thereforeintended that such changes and modifications be covered by the appendedclaims.

1. A battery pack having a battery obtained by packing a battery elementwith a packing member, the battery element being formed by winding orlaminating an anode and a cathode through separators, the battery packcomprising: a frame member surrounding the packing member packing thebattery element; and a coating layer constituted of a curable resinformed on surfaces of the packing member which are surrounded anddemarcated by the frame member.
 2. The battery pack according to claim1, wherein the frame member is formed by framing an upper framing memberhaving a circuit protecting board for protecting the battery elementarranged, a lower framing member, and both side framing members, in amanner surrounding the packing member.
 3. The battery pack according toclaim 1, wherein the curable resin is any of a urethane resin, anacrylic resin, and an epoxy resin.
 4. The battery pack according toclaim 1, wherein the coating layer is formed of the curable resin by aspin coating method.
 5. The battery pack according to claim 1, whereinthe surfaces of the packing member are roughened so as to make athickness of the coating layer uniform.
 6. The battery pack according toclaim 5, wherein an arithmetic average roughness for the surfaceroughness of the packing member is set to a value so as to make thethickness of the coating layer uniform.
 7. The battery pack according toclaim 1, wherein grooves for making a thickness of the coating layeruniform are formed on the surfaces of the packing member.
 8. The batterypack according to claim 1, wherein the packing member is formed of analuminum laminate film.
 9. The battery pack according to claim 1,wherein the packing member is formed of a film having two or morelayers, and contains a polyolefin film.
 10. The battery pack accordingto claim 1, wherein the packing member has a length-to-width ratio ofnot less than 1 and not more than 1.3.
 11. A manufacturing method for abattery pack having a battery, a frame member, and a coating layer, thebattery being obtained by packing a battery element with a packingmember, the battery element being formed by winding or laminating ananode and a cathode through separators, the frame member surrounding thepacking member packing the battery element, the coating being formed ofa curable resin on surfaces of the packing member which are surroundedand demarcated by the frame member, the method comprising the steps of:forming the coating layer to be formed on the surfaces of the packingmember by rotating around a dripping point in which the curable resin isdripped; and thereafter curing the curable resin.